MODULE TITLE: PERFORMING DIESEL ENGINE OPERATION



COMPETENCY-BASED CURRICULUM |[pic] | |

|[pic] |

|Sector: |

|UTILITIES |

|Qualification: |

|Diesel Power Plant Operation |

|and Maintenance NC II |

|[pic] |Technical Education and Skills Development Authority |

| |East Service Road, South Superhighway, Taguig City, Metro Manila |

TABLE OF CONTENTS

Page

A. COURSE DESIGN 1-6

B. MODULES OF INSTRUCTION 7-56

• Basic Competencies 7

o Participating in workplace communication 8-11

o Working in a team environment 12-14

o Practicing career professionalism 15-18

o Practicing occupational health and safety procedures 19-23

• Common Competencies 24

o Reading, interpreting and applying specification and manual 25-28

o Performing shop maintenance 29-33

o Performing mensuration and calculation 34-37

o Performing basic benchwork 38-41

o Performing basic electrical works 42-44

• Core Competencies 45

o Tending diesel engine operation 46-49

o Maintaining and repairing diesel engine 50-56

Course Design

COURSE TITLE : Diesel Power Plant Operation and Maintenance NC II

NOMINAL DURATION : 262 HOURS

COURSE DESCRIPTION :

THIS COURSE IS DESIGNED TO ENHANCE THE KNOWLEDGE, SKILLS AND ATTITUDES OF A TRAINEE/STUDENT IN TENDING DIESEL ENGINE OPERATION, OPERATING DIESEL POWER PLANT, MAINTAINING AND REPAIRING DIESEL ENGINE AND SERVICING ALTERNATOR OR GENERATOR.

This course also participating in workplace communication, working in a team environment, practicing career professionalism, practicing occupational health and safety procedures, applying appropriate sealant and adhesive, reading, interpreting and applying specification and manual and using lubricants.

ENTRY REQUIREMENTS:

TRAINEES OR STUDENTS SHOULD POSSESS THE FOLLOWING REQUIREMENTS:

• can communicate both oral and written in English;

• physically and mentally fit;

• with good moral character; and

• can perform basic mathematical computation

This list does not include specific institutional requirements such as educational attainment and others that may be required from the trainees by the training school delivering the TVET program.

COURSE STRUCTURE:

BASIC COMPETENCIES

(56 HOURS)

|UNITS OF COMPETENCY |MODULE TITLE |LEARNING OUTCOMES |NOMINAL DURATION|

|PARTICIPATE IN WORKPLACE | PARTICIPATING IN |Obtain and convey workplace information |8 hours |

|COMMUNICATION |workplace |Complete relevant work-related document | |

| |communication |Participate in workplace meeting and discussion | |

|Work in a team environment |2.1 Working in a team environment |Describe and identify team role and responsibility |4 hours |

| | |Describe work as a team member | |

|Practice career professionalism |3.1 Practicing career |Integrate personal objectives with organizational goals. |4 hours |

| |professionalism |Set and meet work priorities. | |

| | |Maintain professional growth and development | |

|Practice occupational health and |4.1 Practicing occupational health|Identify hazards and risks |40 hours |

|safety procedures |and safety procedure |Evaluate hazards and risks | |

| | |Control hazards and risks | |

| | |Maintain occupational health and safety awareness | |

COMMON COMPETENCIES

(80 hours)

|Units of Competency |Module Title |Learning Outcomes |Nominal Duration|

|Read, interpret and apply |1.1 Reading, Interpreting And |Identify/accessed manuals and interpret data and |16 hours |

|specification and manual |Applying Specification And Manual |specification. | |

| | |Apply information accessed in manual. | |

| | |Store manual | |

|Perform shop maintenance |2.1 Performing Shop Maintenance |Inspect and clean tools, equipment and the work area. |8 hours |

| | |Store/arrange tools and shop equipment. | |

| | |Dispose waste and used lubricants. | |

| | |Report damaged tools and equipment | |

|Perform mensuration and |3.1 Perforning mensuration and |Select measuring instruments |16 hours |

|calculation |calculation |Carry out measurement and calculation | |

| | |Maintain measuring instruments | |

|Perform basic benchwork |4.1 Performing basic benchwork |Prepare supplies, materials, tools, and equipment |24 hours |

| | |Layout necessary dimensions | |

| | |Perform grinding, cutting, filing, drilling and boring | |

|Perform basic electrical works |5.1 Performing basic electrical |Test power supply and electrical components |16 hours |

| |works |Perform basic repairs and installation | |

CORE COMPETENCIES

(126 HOURS)

|UNITS OF |Module Title |Learning Outcomes |Nominal Duration|

|Competency | | | |

|Tend diesel engine operation |1.1 Tending diesel engine |Perform pre-operation check of diesel engine and auxiliary|32 hours |

| |operation |equipment | |

| | |Tend diesel engine | |

|Maintain and repair diesel engine|3.1 Maintaining and repairing |Service aspiration system |94 hours |

| |diesel engine |Service lube oil system | |

| | |Service of cooling system | |

| | |Service fuel system | |

| | |Check condition of alternator | |

ASSESSMENT METHODS:

• Written test

• Practical test

• Direct observation

• Interview

COURSE DELIVERY:

• LECTURE/DISCUSSION

• Demonstration

• Viewing multimedia

• Hands-on practice

• Project making/ laboratory exercises

• Distance learning

RESOURCES:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL GENERATING SET 160 KW |1 |UNIT |

|PPE |1 |SET |

|INJECTOR CALIBRATING MACHINE |1 |UNIT |

|AIR COMPRESSOR WITH SPRAY GUN |1 |SET |

|INSULATION TESTER |1 |SET |

|MULTI TESTER |1 |SET |

|HYDRAULIC JACK AT LEAST 3 TONNER |2 |SETS |

|CHAIN BLOCK |1 |PC |

| | | |

|MATERIALS | | |

|TURBO CHARGER REPAIR KIT |1 |SET |

|BEARING |1 |PC |

|O-RINGS AND WASHERS |10 |SETS |

|COOLANT PUMP REPAIR KIT |1 |SET |

|LUBE OIL |100 |LTRS |

|DIESEL FUEL |420 |LTRS |

|RAGS |30 |KG |

|SCRUBBING PAD |2 |PCS |

|LOG SHEET/ LOG BOOK AND WRITING TOOLS |1 |SET |

|INHIBITOR |35 |LTRS |

|SOFT WATER |35 |LTRS |

|COOLANT |40 |L |

|DISTILLED WATER |3 |LTR |

|LUBE FILTER |2 |PCS |

|FUEL FILTER |5 |PC |

|AIR FILTER |1 |PC |

|GREASE |2 |KG |

|HI TEMP GREASE |2 |KG |

|BATTERY TERMINAL LUGS AND CLAMPS |2 |SETS |

|TERMINAL LUGS, ½” DIA, |20 |PCS |

|BATTERY CABLE |2 |M |

|AUTOMOTIVE WIRE, NO. 12 AWG |10 |M |

|BATTERY TERMINAL CLEANER 16 OZ |1 |CAN |

|CONTACT CLEANER |1 |CAN |

|PENETRATING OIL |3 |CANS |

|RUST REMOVER |1 |GAL |

|CARBON REMOVER |1 |GAL |

|FOAM |1 |ROLL |

|CARBON REMOVER |1 |GAL |

|DESCALER |2 |GALS |

|STEEL BRUSH |10 |PCS |

|PAINT BRUSH, ASSTD. SIZES |3 |SETS |

|PLASTIC BRUSH |1 |PC |

|NOZZLES |6 |PCS |

|SAFETY SOLVENT |20 |LTRS |

|INSULATING VARNISH |20 |LTRS |

|ELECTRICAL ENAMEL |8 |LTRS |

|ELECTRICAL TAPES |10 |ROLLS |

|RUBBER TAPES |10 |ROLLS |

|COTTON TAPES |3 |ROLLS |

|SPAGHETTI TUBE, 10 MM |5 |M |

|WIRE MARKER |1 |KIT |

|CABLE TIES 6” |24 |PCS |

|REFERENCE MATERIALS |1 |LOT |

|CATALOGS/BROCHURES |1 |LOT |

| | | |

|TOOLS | | |

|PAIL AND FUNNEL |2 |SETS |

|LUBE OIL PUMP |1 |UNIT |

|FUEL PUMP |1 |UNIT |

|COMBINATION WRENCH (8-32) |1 |SET |

|PLIERS AND SCREW DRIVER |1 |SET |

|HYDROMETER |1 |PC |

|VERNIER CALIPER 150 MM |1 |PC |

|MICROMETER 150MM (INSIDE AND OUTSIDE) |1 |SET |

|MAGNETIC DIAL GAUGE |1 |UNIT |

|PAIL AND DIPPER |1 |SET |

|BENCH VISE |1 |UNIT |

|BEARING PULLER |1 |UNIT |

|SOCKET WRENCH (8-32) |1 |SET |

|ALLEN WRENCH |1 |SET |

|FEELER GAUGE |1 |SET |

|A-FRAME |1 |SET |

|SLINGS |2 |SETS |

|EYE BOLTS AND SHACKLES |2 |SETS |

|WOODEN BLOCKS |2 |SETS |

|HEATER |2 |SETS |

|BEARING PULLER |1 |UNIT |

|BEARING HEATER |1 |UNIT |

|HACKSAW |1 |SET |

|ELECTRIC HAND DRILL WITH BITS |1 |SET |

|SLINGS |2 |SETS |

|WOODEN BLOCKS |2 |SETS |

|CRIMPING TOOL |1 |SET |

|SOLDERING SET |2 |SET |

QUALIFICATIONS OF INSTRUCTORS/TRAINERS:

• MUST BE A HOLDER OF DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II OR IT’S EQUIVALENT

• Must have undergone training on Training Methodology II (TM II)

• Must be computer literate

• Must be physically and mentally fit

• *Must have at least 2 years job/industry experience related to Diesel Power Plant Operation and Maintenance specifically in generating set servicing

• *Must be a civil service eligible (for government position or appropriate professional license issued by the Professional Regulatory Commission)

* Optional. Only when required by the hiring institution.

MODULES OF INSTRUCTION

BASIC COMPETENCIES

DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II

BASIC COMPETENCY : COMMUNICATIONS

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION

MODULE TITLE : PARTICIPATING IN WORKPLACE COMMUNICATION

MODULE DESCRIPTOR : This module covers the knowledge, skills and attitudes required to obtain, interpret and convey information in response to workplace requirements.

SUGGESTED DURATION : 8 hours

PREREQUISITE : Receive and Respond to Workplace Communication. (NC I)

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module the students/ trainees will be able to:

LO1. Obtain and convey workplace information

LO2. Complete relevant work related documents.

LO3. Participate in workplace meeting and discussion.

LO1. OBTAIN AND CONVEY WORKPLACE INFORMATION

ASSESSMENT CRITERIA:

1. Specific relevant information is accessed from appropriate sources.

2. Effective questioning, active listening and speaking skills are used to gather and convey information.

3. Appropriate medium is used to transfer information and ideas.

4. Appropriate non-verbal communication is used.

5. Appropriate lines of communication with superiors and colleagues are identified and followed.

6. Defined workplace procedures for the location and storage of information are used.

7. Personal interaction is carried out clearly and concisely.

CONTENTS:

• Parts of speech

• Sentence construction

• Effective communication

CONDITIONS:

The students/ trainees must be provided with the following:

• Writing materials (pen & paper)

• References (books)

• Manuals

METHODOLOGIES:

• Group discussion

• Interaction

• Lecture

• Reportorial

ASSESSMENT METHODS:

• Written test

• Practical/performance test

• Interview

L02. COMPLETE RELEVANT WORK RELATED DOCUMENTS

ASSESSMENT CRTERIA:

1. Ranges of forms relating to conditions of employment are completed accurately and legibly.

2. Workplace data is recorded on standard workplace forms and documents.

3. Basic mathematical processes are used for routine calculations.

4. Errors in recording information on forms/documents are identified and rectified.

5. Reporting requirements to superior are completed according to enterprise guidelines.

CONTENTS:

• Basic mathematics

• Technical writing

• Types of forms

CONDITIONS:

The students/trainees must be provided with the following:

• Paper

• Pencils/ball pen

• Reference books

• Manuals

METHODOLOGIES:

• Group discussion

• Interaction

• Lecture

ASSESSMENT METHODS:

• Written test

• Practical/performance test

• Interview

LO3. PARTICIPATE IN WORKPLACE MEETINGS AND DISCUSSIONS

ASSESSMENT CRITERIA:

1. Team meetings are attended on time.

2. Own opinions are clearly expressed and those of others are listened to without interruption.

3. Meeting inputs are consistent with the meeting purpose and established protocols.

4. Workplace interactions are conducted in a courteous manner appropriate to cultural background and authority in the enterprise procedures.

5. Questions about simple routine workplace procedures and matters concerning conditions of employment are asked and responded.

6. Meeting outcomes are interpreted and implemented.

CONTENTS:

• Sentence construction

• Technical writing

• Recording information

CONDITIONS:

The students/trainees must be provided with the following:

• Paper

• Pencils/ball pen

• References (books)

• Manuals

METHODOLOGIES:

• Group discussions

• Interaction

• Lecture

ASSESSMENT METHODS:

• Written test

• Practical/performance test

• Interview

BASIC COMPETENCY : TEAM WORK

UNIT OF COMPETENCY : WORK IN A TEAM ENVIRONMENT

MODULE TITLE : WORKING IN A TEAM ENVIRONMENT

MODULE DESCRIPTOR : This module covers the knowledge, skills, and attitudes required to relate in a work based environment.

SUGGESTED DURATION : 4 hours

PREREQUISITE : TEAMWORK (NC I)

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the students/ trainees will be able to:

LO1. Describe and identify team role and responsibility.

LO2. Describe work as a team.

LO1. DESCRIBE AND IDENTIFY TEAM ROLE AND RESPONSIBILITY

ASSESSMENT CRITERIA:

1. Role and objective of the team is identified.

2. Team parameters, relationships and responsibilities are identified.

3. Individual role and responsibilities within team environment are identified.

4. Roles and responsibilities of other team members are identified and recognized.

5. Reporting relationships within team and external to team are identified.

CONTENTS:

• Team role.

• Relationship and responsibilities

• Role and responsibilities with team environment.

• Relationship within a team.

CONDITIONS:

The students/ trainees must be provided with the following:

• Standard operating procedure (SOP) of workplace

• Job procedures

• Client/supplier instructions

• Quality standards

• Organizational or external personnel

METHODOLOGIES:

• Group discussion/interaction

• Case studies

• Simulation

ASSESSMENT METHODS:

• Written test

• Observation

• Simulation

• Role playing

LO2. DESCRIBE WORK AS A TEAM MEMBER

ASSESSMENT CRITERIA:

1. Appropriate forms of communication and interactions are undertaken.

2. Appropriate contributions to complement team activities and objectives are made.

3. Reporting using standard operating procedures is followed.

4. Development of team work plans based from team role is contributed.

CONTENTS:

• Communication process

• Team structure/team roles

• Group planning and decision making

CONDITIONS:

The students/trainees must be provided with the following:

• SOP of workplace

• Job procedures

• Organization or external personnel

METHODOLOGIES:

• Group discussion/interaction

• Case studies

• Simulation

ASSESSMENT METHODS:

• Observation of work activities

• Observation through simulation or role play

• Case studies and scenarios.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM

MODULE TITLE : PRACTICING CAREER PROFESSIONALISM

MODULE DESCRIPTOR : This module covers the knowledge, skills and attitudes in promoting career growth and advancement, specifically to integrate personal objectives with organizational goals set and meet work priorities and maintain professional growth and development.

NOMINAL DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

LO1. Integrate personal objectives with organizational goals

LO2. Set and meet work priorities

LO3. Maintain professional growth and development

LO1. INTEGRATE PERSONAL OBJECTIVES WITH ORGANIZATIONAL GOALS

ASSESSMENT CRITERIA:

1. Personal growth and work plans towards improving the qualifications set for professionalism are evident.

2. Intra and interpersonal relationship in the course of managing oneself based on performance evaluation is maintained.

3. Commitment to the organization and its goal is demonstrated in the performance of duties.

4. Practice of appropriate personal hygiene is observed.

5. Job targets within key result areas are attained.

CONTENTS:

• Personal development-social aspects: intra and interpersonal development

• Organizational goals

• Personal hygiene and practices

• Code of ethics

CONDITIONS:

The students/ trainees must be provided with the following:

• Workplace

• Code of ethics

• Organizational goals

• Hand outs and Personal development-social aspects

• CD’s, VHS tapes, transparencies

METHODOLOGIES:

• Interactive -lecture

• Simulation

• Demonstration

• Self-paced instruction

ASSESSMENT METHODS:

• Role play

• Interview

• Written examination

LO2. SET AND MEET WORK PRIORITIES

ASSESSMENT CRITERIA:

1. Competing demands to achieve personal, team and organizational goals and objectives are prioritized.

2. Resources are utilized efficiently and effectively to manage work priorities and commitments.

3. Practices and economic use and maintenance of equipment and facilities are followed as per established procedures.

4. Job targets within key result areas are attained.

CONTENTS:

• Organizational Key Result Areas (KRA)

• Work values and ethical standards

• Company policies on the use and maintenance of equipment

CONDITIONS:

The students/ trainees must be provided with the following

• Hand outs on

- Organizational KRA

- Work values and ethics

- Company policies and standards

- Sample job targets

• Learning guides

• CD’s, VHS tapes, transparencies

METHODOLOGIES:

• Interactive lecture

• Group discussion

• Structured activity

• Demonstration

ASSESSMENT METHODS:

• Role play

• Interview

• Written examination

LO3. MAINTAIN PROFESSIONAL GROWTH AND DEVELOPMENT

ASSESSMENT CRITERIA:

1. Training and career opportunities relevant to the job requirements are identified and availed.

2. Licenses and/or certifications according to the requirements of the qualifications are acquired and maintained

3. Fundamental rights at work including gender sensitivity are manifested/ observed

4. Training and career opportunities based on the requirements of industry are completed and updated.

CONTENTS:

• Qualification standards

• Gender and development (GAD) sensitivity

• Professionalism in the workplace

• List of professional licenses

CONDITIONS:

The students/trainees must be provided with the following:

• Quality standards

• GAD handouts

• CD’s, VHS tapes on professionalism in the workplace

• Professional licenses samples

METHODOLOGIES:

• Interactive lecture

• Film viewing

• Role play/simulation

• Group discussion

ASSESSMENT METHODS:

• Demonstration

• Interview

• Written examination

• Portfolio assessment

UNIT OF COMPETENCY : PRACTICE OCCUPATIONAL HEALTH AND SAFETY PROCEDURES

MODULE TITLE : PRACTICING OCCUPATIONAL HEALTH AND SAFETY PROCEDURES

MODULE DESCRIPTOR : This module covers the knowledge, skills and attitudes required to comply with the regulatory and organizational requirements for occupational health and safety such as identifying, evaluating and maintaining occupational health and safety (OHS) awareness.

NOMINAL DURATION : 40 hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

LO1. Identity hazards and risks

LO2. Evaluate hazards and risks

LO3. Control hazards and risks

LO4. Maintain occupational health and safety awareness

LO1. IDENTIFY HAZARDS AND RISKS

ASSESSMENT CRITERIA:

1. Workplace hazards and risks are identified and clearly explained.

2. Hazards/risks and its corresponding indicators are identified in line with the company procedures.

3. Contingency measures are recognized and established in accordance with organizational procedures.

CONTENTS:

• Hazards and risks identification and control

• Organizational safety and health protocol

• Threshold limit value (TLV)

• OHS indicators

CONDITIONS:

The students/ trainees must be provided with the following:

• Workplace

• Personal protective equipment (PPE)

• Learning guides

• Hand-outs

- Organizational safety and health protocol

- OHS indicators

- Threshold limit value

- Hazards/risk identification and control

• CD’s, VHS tapes, transparencies

METHODOLOGIES:

• Interactive -lecture

• Simulation

• Symposium

• Group dynamics

ASSESSMENT METHODS:

• Situation analysis

• Interview

• Practical examination

• Written examination

LO2. EVALUATE HAZARDS AND RISKS

ASSESSMENT CRITERIA:

1. Terms of maximum tolerable limits are identified based on threshold limit values (TLV).

2. Effects of hazards are determined.

3. OHS issues and concerns are identified in accordance with workplace requirements and relevant workplace OHS legislation.

CONTENTS:

• TLV table

• Philippine OHS standards

• Effects of hazards in the workplace

• Ergonomics

• ECC Regulations

CONDITIONS:

The students/trainees must be provided with the following:

• Hand outs on

- Philippine OHS standards

- Effects of hazards in the workplace

- Ergonomics

- ECC regulations

• TLV table

• CD’s, VHS tapes, transparencies

METHODOLOGIES:

• Interactive lecture

• Situation analysis

• Symposium

• Film viewing

• Group dynamics

ASSESSMENT METHODS:

• Interview

• Written examination

• Simulation

LO3. CONTROL HAZARDS AND RISKS

ASSESSMENT CRITERIA:

1. OHS procedures for controlling hazards and risk are strictly followed.

2. Procedures in dealing with workplace accidents, fire and emergencies are followed in accordance with the organization’s OHS policies.

3. Personal protective equipment (PPE) is correctly used in accordance with organization’s OHS procedures and practices.

4. Procedures in providing appropriate assistance in the event of workplace emergencies are identified in line with the established organizational protocol.

CONTENTS:

• Safety regulations

- Clean air act

- Electrical and fire safety code

- Waste management

- Disaster preparedness and management

• Contingency measures and procedures

CONDITIONS:

The students/trainees must be provided with the following:

• Hand outs on

- Safety Regulations

- Clean air act

- Electrical and fire safety code

- Waste management

- Disaster preparedness and management

- Contingency measures and procedures

• OHS personal records

• PPE

• CD’s, VHS tapes, transparencies

METHODOLOGIES:

• Interactive lecture

• Symposium

• Film viewing

• Group dynamics

• Self-paced instruction

ASSESSMENT METHODS:

• Written examination

• Interview

• Case/situation analysis

• Simulation

LO4. MAINTAIN OCCUPATIONAL HEALTH AND SAFETY AWARENESS

ASSESSMENT CRITERIA:

1. Procedures in emergency related drill are strictly followed in line with the established organization guidelines and procedures.

2. OHS personal records are filled up in accordance with workplace requirements.

3. PPE is maintained in line with organization guidelines and procedures.

CONTENTS:

• Operational health and safety procedure, practices and regulations

• Emergency-related drills and training

CONDITIONS:

The students/trainees must be provided with the following

• Workplace

• PPE

• OHS personal records

• CD’s, VHS tapes, transparencies

• Health record

METHODOLOGIES:

• Interactive lecture

• Simulation

• Symposium

• Film viewing

• Group dynamics

ASSESSMENT METHODS:

• Demonstration

• Interview

• Written examination

• Portfolio assessment

•

MODULES OF INSTRUCTION

COMMON COMPETENCIES

DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUAL

MODULE TITLE : READING, INTERPRETING AND APPLYING SPECIFICATION AND MANUAL

MODULE DESCRIPTION : This module deals with identifying, interpreting and applying service manuals, maintenance procedures manuals, repair manuals and periodical maintenance manual.

NOMINAL DURATION : 16 hours

SUMMARY OF LEARNING OUTCOMES:

UPON COMPLETION OF THE MODULE, THE TRAINEES/ STUDENTS SHOULD BE ABLE TO:

LO1. Identify/accessed manuals and interpret data and specification.

LO2. Apply information accessed in manual.

LO3. Store manual

LO1. IDENTIFY/ACCESS MANUALS AND INTERPRET DATA AND SPECIFICATIONS

ASSESSMENT CRITERIA:

1. APPROPRIATE MANUALS ARE IDENTIFIED AND ACCESSED AS PER JOB REQUIREMENTS.

1. Information and procedures in the manual are interpreted in accordance with industry practices.

2. Relevant sections, chapter of manuals/specifications are located in relation to the work to be performed.

CONTENTS:

• IDENTIFYING APPROPRIATE MANUALS.

• Procedure / techniques in interpreting data and specifications.

• Knowledge and techniques in accessing data and specifications as per job requirements.

• Types of manuals used in automotive industry.

• Identification of symbols used in the manuals.

• Identification of units of measurements.

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Supplies and materials:

o manufacturing specifications

o repair manual

o maintenance manual

o periodic maintenance manual

• Instructional materials

o reference books

o professional emergency

o learning guides

o modules

o CD’s, VHS tapes, transparencies

METHODOLOGIES:

• LECTURE/DEMONSTRATION

• Dualized training

• Distance learning

ASSESSMENT METHODS:

• WRITTEN/ORAL EXAMINATIONS

• Direct observation

• Project method

• Interview

LO2. APPLY INFORMATION ACCESSED IN THE MANUAL

ASSESSMENT CRITERIA:

1. DATA AND SPECIFICATION ARE INTERPRETED ACCORDING TO JOB REQUIREMENT.

3. Work steps are correctly identified in accordance with manufacturer specifications.

4. Manual data is applied according to the given task.

5. All correct sequence and adjustment are interpreted in accordance with information contained on the manual or specification.

CONTENTS:

• INTERPRETING APPROPRIATE DATA AND SPECIFICATIONS.

• Applying data and specification accessed from the manuals as required in the given task.

CONDITIONS:

THE STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Supplies and materials

o manufacturing specifications

o repair manual

o maintenance manual

o periodic maintenance manual

• Instructional materials

o reference books

o learning guides

o modules

o CD’s, VHS tapes, transparencies

METHODOLOGIES:

• LECTURE/DEMONSTRATION

• Dualized training

• Distance learning

ASSESSMENT METHODS:

• WRITTEN/ORAL EXAMINATIONS

• Direct observation

• Project method

• Interview

LO3. STORE MANUAL

ASSESSMENT CRITERIA:

1. MANUALS ARE STORED APPROPRIATELY TO INSURE PREVENTION OF DAMAGE.

6. Manuals are stored properly for easy accessed and ready for updating of information required in the given task.

CONTENTS:

• TECHNIQUES IN STORING MANUALS.

• Procedures in maintaining manuals.

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Supplies/materials

o manufacturing specifications

o repair manual

o maintenance manual

o periodic maintenance manual

• Instructional materials

o reference books

o learning guides

o modules

o CD’s, VHS tapes, transparencies

METHODOLOGIES:

• LECTURE/DEMONSTRATION

• Dualized training

• Distance learning

ASSESSMENT METHODS:

• WRITTEN/ORAL EXAMINATIONS

• Direct observation

• Project method

• Interview

UNIT OF COMPETENCY : Perform Shop Maintenance

MODULE TITLE : Performing Shop Maintenance

MODULE DESCRIPTION : This module covers inspecting, cleaning, arranging and storing tools and shop equipment, including disposal of waste and used lubricant and reporting of damaged tools and equipment in the shop.

NOMINAL DURATION : 8 hours

SUMMARY OF LEARNING OUTCOMES:

UPON COMPLETION OF THIS MODULE, THE TRAINEE/STUDENT MUST BE ABLE TO:

LO1. Inspect and clean tools, equipment and the work area.

LO2. Store/arrange tools and shop equipment.

LO3. Dispose waste and used lubricants.

LO4. Report damaged tools and equipment

LO1. INSPECT AND CLEAN TOOLS, EQUIPMENT AND WORK AREA

ASSESSMENT CRITERIA:

1. TOOLS, EQUIPMENT AND WORK AREA IS INSPECTED AND CLEANED, FREE FROM DUST, GREASE AND OTHER SUBSTANCES.

7. Cleaning solvent is used as per workshop cleaning requirements is observed.

8. Work area is checked and cleaned.

9. Wet surface or spot in the work area is kept dry.

CONTENTS:

• WORKSHOP POLICIES.

• Types and usage of cleaning chemicals.

• Safe handling of equipment and tools.

• Service procedures.

• Equipment maintenance standards.

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Open workshop/garage

• Well ventilated enclosed work and office area

• Wash area and mess hall

• Cleaning chemicals

• Inventory of equipment and tools

• Rugs

• Containers for used oils

• Vehicle

• Oiler

METHODOLOGIES:

• LECTURE

• Demonstration

• Self-paced instruction

• Dual training

ASSESSMENT METHODS:

• DIRECT OBSERVATION

• Practical

• Interview

• Written examination

LO2. STORE/ARRANGE TOOLS AND SHOP EQUIPMENT

ASSESSMENT CRITERIA:

1. TOOLS AND EQUIPMENT ARE ARRANGED AND STORED IN THEIR RESPECTIVE SHELVES/ LOCATION.

10. Corresponding labels are posted and visible.

11. Tools are secured and logged in the record book.

CONTENTS:

• STORAGE AND DISPOSAL OF HAZARDOUS/FLAMMABLE TOOLS/MATERIALS.

• Personal safety procedures.

• Relevant technical information

• Labeling procedures

• Principles of total quality management (TQM) and 5S

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Tool cabinet

• Appropriate tools and equipment

• Tool room

• Fire extinguishers

• Tool kit

• Log/record book

• Labeling materials

METHODOLOGIES:

• INTERACTIVE LECTURE

• Dual training

• Self-paced instruction

• Simulation

ASSESSMENT METHODS:

• PRACTICAL

• Direct observation

• Interview

• Written examination

LO3. DISPOSE WASTE AND USED LUBRICANTS

ASSESSMENT CRITERIA:

1. WASTE AND USED LUBRICANTS ARE DISPOSED IN ACCORDANCE WITH THE STANDARD OPERATIONAL PROCEDURES AND ENVIRONMENTAL REGULATIONS.

12. Containers for waste and used lubricants are properly labeled.

13. Personal safety in disposing waste and used lubricants is evident.

CONTENTS:

• EFFECTS OF AUTOMOTIVE WASTES TO MEN AND ITS ENVIRONMENT.

• Waste management and disposal

• Cleaning chemicals for grease and lubricants

• Labeling procedures and technique

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Waste disposal area

• Oiler

• Handouts for waste management and disposal

• Cleaning chemicals for grease and lubricants

• Containers for waste and used lubricants

METHODOLOGIES:

• INTERACTIVE LECTURE

• Dual training

• Self-paced instruction

• Simulation

• Demonstration

ASSESSMENT METHODS:

• DIRECT OBSERVATION

• Simulation

• Written examination

• Interview

LO4. REPORT DAMAGED TOOLS/EQUIPMENT

ASSESSMENT CRITERIA:

1. COMPLETE INVENTORY OF TOOLS AND EQUIPMENT IS MAINTAINED.

14. Damaged tools/equipment are identified with repair recommendation.

15. Reports prepared on damaged tools/equipment have no error/discrepancy.

CONTENTS:

• CONDUCTING INVENTORY AND PREPARING RECORDS

• Maintenance and safe handling of tools and equipment

• Maintenance and updating of records and reports

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Records and inventory of tools and equipment

• Record books

• Checklist

• Waste disposal reports

• Racks for tools

METHODOLOGIES:

• INTERACTIVE LECTURE

• Dual Training

• Self-paced instruction

• Simulation

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Demonstration

• Direct observation

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATIONS

MODULE TITLE : Performing Mensuration And Calculations

MODULE DESCRIPTION : This unit covers the knowledge, skills and attitudes in identifying and measuring objects based on the required performance standard.

NOMINAL DURATION : 16 hours

SUMMARY OF LEARNING OUTCOMES:

UPON COMPLETION OF THE MODULE, THE TRAINEES/STUDENTS SHOULD BE ABLE TO:

LO1. Select measuring instruments

LO2. Carry out measurements and calculations

LO3. Maintain measuring instrument

LO1. SELECT MEASURING INSTRUMENTS

ASSESSMENT CRITERIA

1. OBJECT OR COMPONENT TO BE MEASURED IS IDENTIFIED, CLASSIFIED AND INTERPRETED TO THE APPROPRIATE REGULAR GEOMETRIC SHAPE.

16. Measuring tools are selected/identified as per object to be measured or job requirements.

17. Correct specifications are obtained from relevant sources.

18. Appropriate measuring instruments are selected according to job requirements.

19. Alternative measuring tools are used without sacrificing cost and quality of work.

CONTENTS:

• LINEAR MEASUREMENTS

• Testing measurements

• Four fundamental operations

• Dimensions

• Units of conversion

• Ratio and proportion

• Trigonometric functions

• Algebraic equations

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

|Tools |Supplies and Materials |

|Micrometer |Protractor |Round |

|Vernier Caliper |Combination Gauge |Square |

|Dial Gauge with Magnitude Standard |Steel Rule |Rectangular |

|Straight Edge |Voltmeter |Triangle |

|Thickness Gauge |Ammeter |Sphere |

|Torque Gauge |Mega Ohmmeter |Conical |

|Small Hole Gauge |KWH Meter | |

|Telescopic Gauge |Gauges | |

|Try-square |Thermometer | |

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Group discussion

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Observation with questioning

LO2. CARRY OUT MEASUREMENTS AND CALCULATIONS

ASSESSMENT CRITERIA:

1. ACCURATE MEASUREMENTS ARE OBTAINED ACCORDING TO JOB REQUIREMENTS.

20. Alternative measuring tools are used without sacrificing cost and quality work.

21. Calculation needed to complete work tasks are performed using the four fundamental operations (addition, subtraction, multiplication and division) including but not limited to trigonometric function and algebraic computations.

22. Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.

23. Numerical computation is self- checked and corrected for accuracy.

24. Instruments are read to the limit of accuracy of the tool.

25. Systems of measurement are identified and converted according to job requirements/ISO.

26. Workpieces are measured according to job requirements.

CONTENTS:

• LINEAR MEASUREMENTS

• Four fundamental operations

• Dimensions

• Units of conversion

• Ratio and proportion

• Trigonometric functions

• Algebraic equations

CONDITIONS: Students/trainees must be provided with the following:

|TOOLS |

|MICROMETER |TORQUE GAUGE |VOLTMETER |

|VERNIER CALIPER |SMALL HOLE GAUGE |AMMETER |

|DIAL GAUGE WITH MAGNITUDE STANDARD |TELESCOPIC GAUGE |MEGA OHMMETER |

|PROTRACTOR |TRY-SQUARE |KWH METER |

|STRAIGHT EDGE |COMBINATION GAUGE |GAUGES |

|THICKNESS GAUGE |STEEL RULE |THERMOMETER |

|SUPPLIES AND MATERIALS | | |

|ROUND |TRIANGLE | |

|SQUARE |SPHERE | |

|RECTANGULAR |CONICAL | |

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Group discussion

• E-learning

ASSESSMENT METHODS:

• ACTUAL DEMONSTRATION

• Direct observation

• Written test/questioning

LO3. MAINTAIN MEASURING INSTRUMENT

ASSESSMENT CRITERIA:

1. MEASURING INSTRUMENTS ARE CLEANED BEFORE AND AFTER USING.

27. Measuring instruments are kept in safe dry place.

28. Proper techniques in using precise instrument according to manufacturer’s standards.

29. Proper handlings of measuring instruments are observed in accordance with industry standards.

CONTENTS:

• HANDLING AND CARING OF MEASURING INSTRUMENTS.

• Calibrating measuring instrument.

• Safe handling and procedures in using measuring instruments.

• Storing of measuring instruments.

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Equipment/tools/instrument

o Computer

o VHS player

o OHP

o Vernier calipers, micrometer, bore gauge, feeler gauge

o Steel rule, push rule

o Supplies/materials

o Paper

o Pencil

o Engine parts

• Instructional materials

o Reference books

o Learning guides

o Modules

o CD’s VHS tapes, Transparencies

METHODOLOGIES:

• LECTURE

• Demonstration

• Simulation

ASSESSMENT METHODS:

• WRITTEN EXAMINATION

• Direct observation

• Oral examination

unit OF COMPETENCY : PERFORM BASIC BENCHWORK

MODULE TITLE : PERFORMING BASIC BENCHWORK

MODULE DESCRIPTION : This module covers the knowledge, skills and attitudes required in performing basic bench work.

NOMINAL DURATION : 24 hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module, the trainees/students should be able to:

LO1. Prepare supplies, materials, tools, and equipment

LO2. Layout necessary dimensions

LO3. Perform grinding, cutting, filing, drilling and boring

LO1. PREPARE SUPPLIES, MATERIALS, TOOLS, AND EQUIPMENT

ASSESSMENT CRITERIA:

1. SUPPLIES, MATERIALS, TOOLS, AND EQUIPMENT ARE IDENTIFIED ACCORDING TO JOB REQUIREMENTS.

30. Supplies, materials, tools, and equipment are prepared according to job requirements.

31. Supplies, materials, tools, and equipment are checked according to job requirements.

32. Tools and equipment condition are checked following SOP.

CONTENTS:

• COMMUNICATION SKILLS

• Materials, tools and equipment uses and specifications

CONDITIONS:

STUDENTS / TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Blueprint

• Catalogue

• List of tools and equipment

• Forms (request & bill of materials)

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Direct laboratory experience

• Group discussion

• Industry Immersion

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Observation with questioning

• Demonstration with questioning

LO2. LAYOUT NECESSARY DIMENSIONS

ASSESSMENT CRITERIA:

1. LAYOUT DIMENSIONS ARE IN ACCORDANCE WITH JOB REQUIREMENTS.

2. Dimensions are laid out within the required tolerance.

3. Dimensions are checked within the actual work plan.

4. Proper usage of measuring instrument is observed.

CONTENTS:

• MEASURING TOOLS FUNCTIONS AND USAGE

• Communication skills

• Trade mathematics

• Mensuration

• Calculation

• Conversion

• Plan Specifications

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Measuring Tools

• Drawing Instruments

• Work Plan

• Markers

• Calculator

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Direct laboratory experience

• Group discussion

• Industry Immersion

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Observation with questioning

• Demonstration with questioning

LO3. PERFORM GRINDING, CUTTING, FILING, DRILLING AND BORING

ASSESSMENT CRITERIA:

1. WORKPIECES ARE CUT ACCORDING TO REQUIRED MEASUREMENT.

2. Workpieces are free from bores and sharp edge.

3. Welded joints are free from weld defects.

4. Appropriate Personal Protective Equipment (PPE) is applied.

5. Safety work habits are observed.

6. Worksite is cleaned and cleared of debris and left in safe state according to occupational health and safety (OH & S)

CONTENTS:

• TOOLS AND EQUIPMENT USAGE AND SPECIFICATIONS

• Grinding, cutting, drilling, filing techniques

• Basic welding principles and application

• Applied occupational health and safety (OH & S)

CONDITIONS:

STUDENTS / TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Personal Protective Equipment (PPE)

• Tools and equipment

• Measuring instruments

• Work plan

• required supplies and materials

• Worksite

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Direct laboratory experience

• Group discussion

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Observation with questioning

• Demonstration with questioning

unit OF COMPETENCY : PERFORM BASIC ELECTRICAL WORKS

MODULE TITLE : PERFORMING BASIC ELECTRICAL WORKS

MODULE DESCRIPTION : This module covers the knowledge, skills and attitudes required in performing basic electrical works.

NOMINAL DURATION : 16 hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module, the trainees/students should be able to:

LO1. Test power supply and electrical components

LO2. Perform basic repairs and installation

LO1. TEST POWER SUPPLY AND ELECTRICAL COMPONENTS

ASSESSMENT CRITERIA:

1. REQUIRED MATERIALS, TOOLS AND EQUIPMENT ARE PREPARED IN LINE WITH WORK REQUIREMENTS

2. Required procedure in using testing instrument are applied

3. Power supply and electrical components are checked with the manufacturers specification

4. Identified defects of power supply and electrical components are recorded

5. Safe working habits are observed

CONTENTS:

• FUNCTIONS AND USES OF TESTING INSTRUMENTS

• Basic electricity

• Electrical safety and hazards

• Testing procedures

CONDITIONS:

STUDENTS/TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Tools and testing instruments

• Required electrical components

• Personal protective equipment

• Worksite

• Trainer / workshop

• Courseware

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Group discussion

ASSESSMENT METHODS:

•

• INTERVIEW

• Written examination

• Observation with questioning

• Demonstration with questioning

LO2. PERFORM BASIC REPAIRS AND INSTALLATION

ASSESSMENT CRITERIA:

1. ELECTRICAL FIXTURES ARE FIXED IN LINE WITH STANDARD OPERATING PROCEDURES (SOP).

2. Defective electrical components are replaced with the same specifications.

3. Testing of units after repair is performed.

4. Work instructions are followed to ensure safety at work.

5. Workplace is cleaned and cleared of debris and in a safe state of condition and in line with occupational health and safety (OH & S) regulations.

CONTENTS:

• TYPES OF ELECTRICAL FIXTURES

• Testing procedures

• Electrical safety and hazards

• Applied occupational health & safety (OH & S)

CONDITIONS:

STUDENTS / TRAINEES MUST BE PROVIDED WITH THE FOLLOWING:

• Workplace

• Required electrical fixtures and components

• Tools and testing instruments

• Trainer / mock ups

• Personal protective equipment(PPE)

• Trainer/ mock ups

• Courseware

METHODOLOGIES:

• SELF-PACED INSTRUCTION

• Film viewing

• Direct laboratory experience

• Industry immersion

• E-learning

ASSESSMENT METHODS:

• INTERVIEW

• Written examination

• Observation with questioning

• Demonstration with questioning

MODULES OF INSTRUCTION

CORE COMPETENCIES

DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II

unit OF COMPETENCY : Tend Diesel Engine Operation

MODULE TITLE : TENDING DIESEL ENGINE OPERATION

MODULE DESCRIPTION : This unit covers the required performance in executing the operation of diesel engine and its auxiliary equipment.

NOMINAL DURATION : 32 hours

PRE-REQUISITE : A trainee who wants to takes this module must be familiar with the diesel engine operation

SUMMARY OF LEARNING OUTCOMES

UPON COMPLETION OF THE MODULE, THE TRAINEES/STUDENTS SHOULD BE ABLE TO:

LO1. Perform pre-operation check of diesel engine and auxiliary equipment

LO2. Tend diesel engine

LO1. PERFORM PRE-OPERATION CHECK OF DIESEL ENGINE AND AUXILIARY EQUIPMENT

Assessment criteria:

1. PREPARATION OF COOLING SYSTEM IS PERFORMED FOLLOWING ESTABLISHED PROCEDURES.

2. Preparation of fuel system is performed in accordance with established procedure.

3. Preparation of lube oil system is done in accordance with established procedure.

4. Preparation of aspiration system is done in accordance with established procedure.

5. Result of walk around check is recorded and reported using log sheet and log book.

6. Preparation of DC system is performed in accordance with established procedure.

7. Checking of speed regulating system is performed in accordance with established procedure

CONTENT:

• COOLING SYSTEM OPERATION AND MAINTENANCE

• Fuel system operation and maintenance

• Lube oil system operation and maintenance

• Aspiration system operation and maintenance

• DC system operation and maintenance

• Speed regulating system operation and maintenance

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL GENERATING SET 160 KW |1 |UNIT |

|PPE |1 |SET |

| | | |

|MATERIALS | | |

|INHIBITOR |35 |LTR |

|SOFT WATER |35 |LTR |

|LUBE OIL |60 |LTR |

|FUEL |210 |LTR |

|DISTILLED WATER |3 |LTR |

|LUBE FILTER |2 |PCS |

|FUEL FILTER |1 |PC |

|AIR FILTER |1 |PC |

|RAGS |10 |KG |

|GREASE |1 |KG |

|BATTERY TERMINAL LUGS AND CLAMPS |2 |SET |

|BATTERY CABLE |2 |M |

|PLASTIC BRUSH |1 |PC |

|BATTERY TERMINAL CLEANER 16 OZ |1 |CAN |

|LOG SHEET/ LOG BOOK AND WRITING TOOLS |1 |SET |

| | | |

|TOOLS | | |

|PAIL AND FUNNEL |2 |SETS |

|LUBE OIL PUMP |1 |UNIT |

|FUEL PUMP |1 |UNIT |

|HYDROMETER |1 |PC |

|COMBINATION WRENCH (8-32) |1 |SET |

|PLIERS AND SCREW DRIVER |1 |SET |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

LO2. tend DIESEL ENGINE

ASSESSMENT CRITERIA:

1. ENGINE RUNNING CONDITION IS MONITORED FOR NORMAL FUNCTION BASED ON INDICATING PARAMETERS

2. Routine check is performed in accordance with equipment checklist

3. Unit abnormalities are recorded and reported to using log book and log sheets

4. Shutdown procedure is coordinated with the control operator in accordance with enterprise policy.

5. Emergency stop push button is engaged in accordance with the operations manual.

6. Daily operation is recorded and reported in accordance with the enterprise policy.

CONTENT:

• NORMAL AND ABNORMAL CONDITIONS OF DIESEL ENGINE OPERATION

• Procedure in performing routine check

• Procedure in shutting down the unit

• Preparation of spot report

• Preparation of daily operational report

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL GENERATING SET 160 KW |1 |UNIT |

|PPE |1 |SET |

| | | |

|MATERIALS | | |

|LUBE OIL |4 |LTR |

|FUEL |210 |LTR |

|RAGS |1 |KG |

|LOG SHEET/ LOG BOOK AND WRITING TOOLS |1 |SET |

| | | |

|TOOLS | | |

|PAIL AND FUNNEL |2 |SETS |

|LUBE OIL PUMP |1 |UNIT |

|FUEL PUMP |1 |UNIT |

|COMBINATION WRENCH (8-32) |1 |SET |

|PLIERS AND SCREW DRIVER |1 |SET |

METHODOLOGY:

• LECTURE

• Discussion

• Demonstration

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

• unit OF COMPETENCY : MAINTAIN AND REPAIR DIESEL ENGINE

MODULE TITLE : MAINTAINING AND REPAIRING DIESEL ENGINE

MODULE DESCRIPTION : This module covers the required performance in maintaining and servicing the Diesel Engine Systems

NOMINAL DURATION : 94 hours

PRE-REQUISITE : A trainee who wants to takes this module must be familiar with the diesel engine operation

Summary of learning outcomes

UPON COMPLETION OF THE MODULE, THE TRAINEES/STUDENTS SHOULD BE ABLE TO:

LO1. Service aspiration system

LO2. Service lube oil system

LO3. Service of cooling system

LO4. Service fuel system

LO5. Maintain condition of alternator

LO1. Service Aspiration System

Assessment criteria:

1. TURBOCHARGER IS MAINTAINED BASED ON PREVENTIVE MAINTENANCE SCHEDULE (PMS)

33. Cleaning or replacement of air filter is done following manufacturer’s recommendation

34. Air filter casing is cleaned and freed of dust or foreign particles as cleaning or replacement of filter occurs.

CONTENT:

• MAINTENANCE AND REPAIR OF TURBO CHARGER

• Servicing air filters

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL ENGINE, 160KW |1 |UNIT |

|PPE |1 |SET |

|COMPRESSOR |1 |SET |

| | | |

|MATERIALS | | |

|RAGS |2 |KG |

|FOAM |1 |ROLL |

|PAINT BRUSH, ASSTD. SIZES |6 |PC |

|TURBO CHARGER REPAIR KIT |1 |SET |

|AIR FILTER |1 |PC |

| | | |

|TOOLS | | |

|MECHANICAL TOOLS (I.E. WRENCHES, PLIERS, SCREW DRIVERS, ETC.) |1 |SET |

|VERNIER CALIPER 150 MM |1 |PC |

|MICROMETER 150MM (INSIDE AND OUTSIDE) |1 |SET |

|MAGNETIC DIAL GAUGE |1 |UNIT |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

• Practicum

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

LO2. Service Lube Oil System

Assessment criteria:

1. CHANGE OIL IS PERFORMED ACCORDING TO PMS

35. Oil cooler tube stack is serviced according to PMS

CONTENT:

• CHANGE OIL PROCEDURE

• Servicing of lube oil cooler

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL ENGINE, 160KW |1 |UNIT |

|PPE |1 |SET |

|COMPRESSOR |1 |SET |

|PRESSURE WASHER |1 |UNIT |

| | | |

|MATERIALS | | |

|RAGS |5 |KG |

|PENETRATING OIL |3 |CAN |

|STEEL BRUSH |5 |PC |

|GREASE |1 |PACK |

|LUBE OIL |27 |L |

|CARBON REMOVER |1 |GAL |

|DESCALER |1 |GAL |

|OIL FILTER |2 |PCS |

|O-RING |2 |PCS |

| | | |

|TOOLS | | |

|MECHANICAL TOOLS (I.E. WRENCHES, PLIERS, SCREW DRIVERS, ETC.) |1 |SET |

|PAIL AND DIPPER |1 |SET |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

• Practicum

ASSESSMENT METHODs:

• WRITTEN

• Demonstration with oral questioning

• LO3. Service of Cooling System

Assessment criteria:

1. COOLING SYSTEM IS CHECKED FOR LEAKS VISUALLY.

2. Radiator is serviced following enterprise policy

3. Thermostat is serviced in accordance with manufacturer’s instruction

4. Coolant pump is serviced in accordance with manufacturer’s instruction

5. Coolant is refilled in accordance to the manufacturer’s instruction.

6. Oil cooler tube stack is serviced according to PMS

CONTENT:

• SERVICING RADIATOR

• Servicing coolant pump

• Thermostat

• Servicing oil cooler

• Coolant rail

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL ENGINE 160 KW |1 |UNIT |

|PPE |1 |SET |

|COMPRESSOR |1 |SET |

|HYDRAULIC JACK 10 TONS |1 |UNIT |

|MATERIALS | | |

|RAGS |5 |KG |

|STEEL BRUSH |5 |PCS |

|LUBE OIL |1 |L |

|COOLANT |40 |L |

|DESCALER |1 |GAL |

|RUST REMOVER |1 |GAL |

|CARBON REMOVER |1 |GAL |

|O-RING |2 |PCS |

|COOLANT PUMP REPAIR KIT |1 |SET |

|PAINT BRUSH, ASSTD. SIZES |6 |PC |

|TOOLS | | |

|MECHANICAL TOOLS (I.E. WRENCHES, PLIERS, SCREW DRIVERS, ETC.) |1 |SET |

|BENCH VISE |1 |UNIT |

|PAIL AND DIPPER |1 |SET |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

• Practicum

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

• LO4. Service Fuel System

Assessment criteria:

1. FUEL FILTER IS REPLACED IN ACCORDANCE WITH MANUFACTURER’S INSTRUCTION AND PMS.

36. Fuel oil/water separator is drained to ensure that the system is free from foreign elements.

37. Injection pump timing is checked according to manufacturer’s instruction

38. Fuel injectors are calibrated following manufacturer’s instruction

39. Servicing and calibration of injection pump is recommended in accordance with PMS and enterprise policy.

CONTENT:

• SERVICING OF FUEL OIL SYSTEM

• Fuel filter

• Fuel and water separator

• Fuel injectors

• Injection pump

CONDITIONS: Students / trainees must be provided with the following:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|DIESEL GENERATING SET 160 KW |1 |UNIT |

|PPE |1 |SET |

|INJECTOR CALIBRATING MACHINE |1 |UNIT |

| | | |

|MATERIALS | | |

|RAGS |5 |KG |

|DIESEL FUEL |5 |L |

|FUEL FILTER |5 |L |

|O-RINGS AND WASHERS |6 |SETS |

|NOZZLES |6 |PCS |

| | | |

|TOOLS | | |

|MECHANICAL TOOLS (I.E. WRENCHES, PLIERS, SCREW DRIVERS, ETC.) |1 |SET |

|PAIL AND DIPPER |1 |SET |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

• Practicum

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

• LO5. CHECK CONDITION OF ALTERNATOR

ASSESSMENT CRITERIA:

1. CONDITIONS OF EXCITER ROTOR, EXCITER STATOR, MAIN ROTOR, AND MAIN STATOR WINDINGS ARE ASSESSED USING PRESCRIBED METHODS.

40. Conditions of compounding transformer, PT’s, CT’s, and Diodes are tested and assessed using prescribed methods.

41. Component repair or replacements are recommended in accordance with enterprise policy.

CONTENT:

• PROCEDURE IN TESTING OF EXCITER ROTOR AND STATOR

• Procedure in testing of main rotor and stator

• Procedure in testing Compounding Transformer

• Procedure in testing Current and Potential Transformer

• Procedure in testing Diodes

• Common defects and remedies

• Procedure in re-insulating windings

CONDITIONS:

|ITEM DESCRIPTION |QTY |UNIT |

|EQUIPMENT | | |

|ALTERNATOR/GENERATOR, 160 KW |1 |UNIT |

|PPE |1 |SET |

|AIR COMPRESSOR WITH SPRAY GUN |1 |SET |

|INSULATION TESTER |1 |SET |

|MULTI TESTER |1 |SET |

|MATERIALS | | |

|SAFETY SOLVENT |20 |LTR |

|BEARING |1 |PC |

|INSULATING VARNISH |20 |LTR |

|ELECTRICAL ENAMEL |8 |LTR |

|BRUSH 2”, 3”, 4” |9 |PC |

|TERMINAL LUGS, ½” DIA, |20 |PC |

|COTTON TAPES |3 |ROLL |

|RAGS |10 |KG |

|AUTOMOTIVE WIRE, NO. 12 AWG |10 |M |

|HI TEMP GREASE |2 |KG |

|RUBBER TAPES |10 |ROLL |

|ELECTRICAL TAPES |10 |ROLL |

|SPAGHETTI TUBE, 10 MM |5 |M |

|WIRE MARKER |1 |KIT |

|SCRUBBING PAD |2 |PC |

|CABLE TIES 6” |24 |PC |

|TOOLS | | |

|HEATER |2 |SETS |

|BEARING PULLER |1 |UNIT |

|BEARING HEATER |1 |UNIT |

|CHAIN BLOCK |1 |PC |

|COMBINATION WRENCH (8-32) |1 |SET |

|PLIERS AND SCREW DRIVER |1 |SET |

|A-FRAMES |1 |SET |

|HYDRAULIC JACK 3 TONNER |2 |SET |

|HACKSAW |1 |SET |

|ELECTRIC HAND DRILL WITH BITS |1 |SET |

|SLINGS |2 |SET |

|EYE BOLTS AND SHACKLES |2 |SET |

|WOODEN BLOCKS |2 |SET |

|CRIMPING TOOL |1 |SET |

|SOLDERING SET |2 |SET |

METHODOLOGIES:

• LECTURE

• Discussion

• Demonstration

• Practicum

ASSESSMENT METHODS:

• WRITTEN

• Demonstration with oral questioning

What is Competency-Based Curriculum (CBC)

❑ A competency-based curriculum is a framework or guide for the subsequent detailed development of competencies, associated methodologies, training and assessment resources.

❑ The CBC specifies the outcomes which are consistent with the requirements of the workplace as agreed through the industry or community consultations.

❑ CBC can be developed immediately when competency standards exist.

❑ When competency standards do not exist, curriculum developers need to clearly define the learning outcomes to be attained. The standard of performance required must be appropriate to industry and occupational needs through the industry/enterprise or specified client group consultations.

These materials are available in both printed and electronic copies.

For more information please contact:

Technical Education and Skills Development Authority (TESDA)

Telephone Nos.: 893-8281, 817-4076 to 82 loc. 611 to 630, 631 and 635 or visit our website: .ph

or the TESDA Regional or Provincial Office nearest you.

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